Air distribution for mattresses

Patent metadata

Field	Value
Publication number	US-11751697-B2
Application number	US-202217729965-A
Country	US
Kind code	B2
Filing date	Apr 26, 2022
Priority date	Apr 6, 2020
Publication date	Sep 12, 2023
Grant date	Sep 12, 2023

Abstract

A ventilated mattress includes a ventilation system with an air distribution layer and a gel cushioning layer over the air distribution layer. The air distribution layer may include channels in a surface thereof, while voids that extend through an entire thickness of the gel cushioning layer may include voids that communicate with the channels. As the ventilation system forces air into the air distribution layer, the air may flow through the channels, into and through the voids of the gel cushioning layer, and to a top of the ventilated mattress.

First claim

What is claimed:

1. A mattress, comprising:
at least one base cushioning layer;
ventilation equipment;
an air distribution layer over the at least one base cushioning layer and including channels that extend partially into the air distribution layer and receive airflow from the ventilation equipment, the channels including:
at least one first channel extending across a width of the air distribution layer; and
second channels extending across a length of the air distribution layer and intersecting the at least one first channel.

2. The mattress of claim 1 , further comprising:
a frame defining a pocket within which the at least one base cushioning layer and the ventilation equipment are located.

3. The mattress of claim 2 , wherein the frame includes ventilation features that enable air to be drawn from locations outside of the mattress into the ventilation equipment of the mattress.

4. The mattress of claim 1 , further comprising:
a foam layer covering the ventilation equipment, beneath the air distribution layer.

5. The mattress of claim 1 , further comprising:
a gel cushioning layer atop the air distribution layer.

6. The mattress of claim 5 , wherein the gel cushioning layer includes voids extending completely through a thickness thereof.

7. The mattress of claim 6 , wherein the voids communicate with the channels to receive the airflow from the channels and communicate the airflow toward a top surface of the mattress.

8. The mattress of claim 5 , wherein the gel cushioning layer comprises a grid defined by an elastomeric material and defining walls of an array of buckling columns.

9. The mattress of claim 5 , further comprising:
a top edge on the air distribution layer and surrounding the gel cushioning layer.

10. The mattress of claim 9 , wherein the at least one first channel is located adjacent to a foot of the mattress.

11. The mattress of claim 1 , further comprising:
a support layer over the at least one base cushioning layer and supporting the air distribution layer.

12. The mattress of claim 1 , wherein the at least one base cushioning layer comprises:
a first base cushioning layer; and
a second base cushioning layer.

13. The mattress of claim 12 , further comprising:
an intervening layer between the first base cushioning layer and the second base cushioning layer.

14. The mattress of claim 1 , wherein the at least one base cushioning layer comprises an array of mattress coils.

15. The mattress of claim 1 , wherein the at least one base cushioning layer comprises an air bladder.

16. The mattress of claim 15 , wherein the air bladder comprises a plurality of air chambers.

17. An air distribution layer of a ventilation system for a mattress, comprising:
a foam layer; and
channels that extend partially into a surface of the foam layer and receive airflow from ventilation equipment, the channels including:
at least one first channel extending across a width of the air distribution layer; and
second channels extending across a length of the air distribution layer and intersecting the at least one first channel.

18. The air distribution layer of claim 17 , wherein the at least one first channel comprises a plurality of first channels.

19. The air distribution layer of claim 17 , wherein:
the at least one first channel receives the airflow from the ventilation equipment and provides a first airflow to a first area over the foam layer; and
the second channels receive the airflow from the ventilation equipment and provide a second airflow to a second area over the foam layer.

20. The air distribution layer of claim 19 , wherein the first airflow has a first rate that exceeds a second rate of the second airflow.

Assignees

• Purple Innovation Llc

Inventors

• Grutta James T
• Pearson Brett
• Carter Aubree

Classifications

• A47C21/044 Primary

  with active means, e.g. by using air blowers or liquid pumps · CPC title

• A47C27/082

  with non-manual inflation, e.g. with electric pumps · CPC title

• A47C27/083

  with pressure control, e.g. with pressure sensors · CPC title

• A47C27/10

  with two or more independently-fillable chambers · CPC title

• A47C27/18

  in combination with inflatable bodies · CPC title